Panelling system formed from panels defined by tongue and groove strips

ABSTRACT

A panelling system preferably for floors is defined by a series of panels each formed of a plurality of tongue and groove main floor plank strips arranged side edge to side edge and cut to a common length with a tongue along one cut edge and a groove along the other. At the edges are attached edge strips formed also from the flooring planks with tongue and groove and fastened together to form a common panel member for transportation and installation. The outwardly facing edge of each edge has a tongue or groove for mating with a groove or tongue of a next adjacent panel. The strips are fastened by pins from the rear or by a bonded sheet material on the rear.

This application is a continuation-in-part application from applicationSer. No. 11/760,093 filed Jun. 8, 2007.

This invention relates to a panelling system defined by a plurality ofinter-engaging panels. The system is primarily designed for flooring butcan be used for other surfaces requiring to be paneled with anattractive layer of a covering material formed in individual panels. Thesystem is primarily designed for use with panels formed of wood butother materials can be used either to form the entire panel or a part ofthe panel.

BACKGROUND OF THE INVENTION

Various techniques have been proposed for the manufacture of wood panelflooring. Conventionally wood panel flooring is formed as tongue andgroove planks which are arranged edge to edge so that the tongue of oneprojects into a groove of the next. This construction is time consumingand relatively inaccurate so that gaps can be exposed leading to anunattractive appearance.

Floor panels in rectangular shape have been proposed which generallyagain connect one to the next using a tongue and groove arrangement soas to provide an improved laying system. Often such panels are formedfrom laminated or other non-wood materials and hence are not accepted asa high quality wood product.

In published US Patent Application 2006/0076394 published Apr. 13, 2006and in corresponding Canadian Application Serial No: 2,525,516originally published Mar. 4, 2005 of Kelly Gibson, one of the inventorsherein, is disclosed a panelling system primarily for flooring which isformed from a plurality of wood floor panel members defined by arectangular panel formed of wood and along two opposed side edges adecorative dividing strip extending along the length of the side edgeand having a top surface of the strip lying in a common plane with theupper surface of the panel with the other opposed side edges of thepanel being exposed for butting directly against a next adjacent panel,The dividing strips project beyond an end of the side edge and are cutat 45 degrees to form a pointed portion having an apex at a position midway through the thickness of the dividing strip such that four dividingstrips, when the panels are laid on the floor, meet at the junctionbetween four of the panels with the apexes in contact at a center of therectangular area at the junction. This arrangement as disclosed wasproposed for use with rectangular panels of solid wood or for deckstrips and as such was not suitable for high quality interior flooringThe disclosure of this published application is incorporated herein byreference.

SUMMARY OF THE INVENTION

It is one object of the invention to provide a panelling system definedby a plurality of inter-engaging panels defined by tongue and groovestrips.

According to one aspect of the invention there is provided a panellingsystem comprising:

a plurality of panel members for locating on a supporting surfacegenerally edge to edge in an array to cover the supporting surface;

each panel member having a front surface for defining an exposed surfaceof the panelling system, a rear surface for engaging the supportingsurface and a plurality of side edges;

each panel member comprising:

a plurality of main strips arranged side edge to side edge;

each main strip having a tongue along one side edge and a correspondinggroove along an opposed side edge;

so that the main strips are connected side by side by interconnection ofthe tongues and the grooves;

wherein the main strips have along a first end of the main strips atongue and have along a second end of the main strips a groove;

a first edge strip extending along the first ends of the main stripsacross at least some of the main strips;

a second edge strip extending along the second ends of the main stripsacross at least some of the main strips;

wherein each of the edge strips has a front surface of the dividingstrip lying in a common plane with the front surfaces of the main stripsto define the front surface of the panel;

wherein each of the edge strips has a tongue along one side edge and acorresponding groove along an opposed side edge;

wherein the first edge strip has the groove thereof engaged with thetongue along the first ends of the main strips;

wherein the second edge strip has the tongue thereof engaged with thegroove along the second ends of the main strips;

and wherein the edge strips and the main strips are fastened together toform a common panel member for transportation and installation.

Preferably each of the main strips has the same width between the sideedges so that the panel member can be formed from a common supply ofidentical strip members. However this is not essential and differentwidths may be used to obtain different visual effects.

Also it is preferable that each edge strip has substantially the samewidth as the main strips for the same reasons.

The panels are preferably arranged so that when arranged edge to edgewith the next adjacent panels the whole panel assembly covers thesupporting surface in the sense that there are no spaces between thepanels. However is will be appreciated as in any panelling system thatparts of the supporting surface may need to be finished using cutsections of panels where the edges of the panels do not coincide withthe edges of the floor or other supporting surface.

According to a second aspect of the invention there is provided apanelling system comprising:

a plurality of panel members for locating on a supporting surface;

each panel member having a front surface for defining an exposed surfaceof the panelling system, a rear surface for engaging the supportingsurface and a plurality of side edges;

the panel members being of polygonal shape in plan view such that thepanels can be arranged in an edge to edge array covering the supportingsurface;

each panel member comprising:

a plurality of main strips arranged side edge to side edge;

each main strip having a tongue along one side edge and a correspondinggroove an opposed side edge;

so that the main strips are connected side by side to form a centerpanel portion by interconnection of the tongues and the grooves;

the center panel portion being polygonal in plan view having a number ofsides;

each of the sides having either a tongue or a groove therealong;

a plurality of edge strips equal in number to the number of sides;

wherein each of the edge strips has a front surface of the dividingstrip lying in a common plane with the front surfaces of the main stripsto define the front surface of the panel;

wherein each of the edge strips has a tongue along one side edge and acorresponding groove along an opposed side edge;

wherein the edge strips are each arranged in engagement with arespective side of the center panel portion with the tongue or groovethereof engaged with the groove or tongue of the respective side;

wherein the edge strips present outwardly of the panel either a tongueor a groove for engaging a groove or a tongue of an edge strip of a nextadjacent panel;

and wherein the edge strips and the main strips are fastened together toform a common panel member for transportation and installation.

Preferably each of the main strips has the same width between the sideedges.

Preferably each edge strip has substantially the same width as the mainstrips.

Preferably a longitudinal line along the main strips lies at an angleless than 90 degrees to a longitudinal line along an edge stripconnected to ends of the main strips.

Preferably the main strips define an area which is square with foursides each receiving a respective edge strip.

Preferably the main strips define an area which is triangular with threesides each receiving a respective edge strip.

Preferably the main strips define an area which is hexagonal with sixsides each receiving a respective edge strip.

Preferably the edge strips have ends butting at a line extendingoutwardly from an apex of the center panel portion.

Preferably the line extending outwardly from the apex intersects acenter of the panel so that the edge strips are symmetrical.

In one particularly important arrangement, the dividing strips and themain strips are fastened together by a plurality of pins each insertedat a butting edge between one strip and a next adjacent strip throughthe rear surface at a groove on one side of the butting edge andextending into a tongue in the groove with a front end of the pinterminating at a position spaced from the front surface.

The term “pin” is intended to include nails or other elongate mechanicalfasteners with or without a discernible head which can be driven fromone end into the material. The front end may or may not be sharpened.The pin may include a second co-operating pin in the form of a staplewhere the two pins are connected side by side

Preferably wherein each pin is inclined at an angle to a planecontaining the butting edge so as to pass through the plane.

Preferably each main strip is fastened to each next adjacent strip by aplurality of the pins at spaced positions along the main strips and eachdividing strip is fastened to the main strips by a plurality of the pinsat spaced positions along the dividing strip.

Preferably each pin is inserted such that it is countersunk from therear surface.

Preferably at least one of the main strips is formed from two stripportions butted end to end and wherein the ends are connected by atongue and groove connection. This allows material to be used withoutany waste. However the main strips may also have no joints between theends by cutting and scrapping pieces which are insufficient in length tospan the distance between the dividing strips.

The panels can be fastened to a sub-floor using screws (or otherfasteners) passing through a drilled hole in the panel covered by adecorative plug, or may be attached using an adhesive layer between thesub floor and the panels, or may be fastened using traditional nailsthrough the tongues as in traditional tongue and groove flooring.

BRIEF DESCRIPTION OF THE DRAWINGS

One embodiment of the invention will now be described in conjunctionwith the accompanying drawings in which:

FIG. 1 is a plan view of a panel of a flooring system according to thepresent invention.

FIG. 2 is a plan view of four such panels assembled to form part of theflooring system.

FIG. 3 is a cross sectional view through a junction between two boardsof the panel of FIG. 1 showing the pin connection therebetween.

FIGS. 4 and 5 show schematically a series of steps in a method forassembly of the panel of FIG. 1.

FIG. 6 is a more detailed view of the carousel for forming and attachingthe dividing strips.

FIG. 7 is a cross sectional view similar to that of FIG. 3 through ajunction between two boards of the panel of FIG. 1 showing analternative mode of connection therebetween.

FIG. 8 is a plan view of a plurality of assembled panels of a furtherembodiment of flooring system according to the present invention wherethe individual panels are hexagonal and there is provide an edge stripon each of the six sides.

FIG. 9 is a plan view of a panel of one square panel of a furtherembodiment of a flooring system according to the present invention.

FIG. 10 is a plan view of a panel of one square panel of a yet furtherembodiment of a flooring system according to the present invention andthere is provide an edge strip on each of the four sides.

FIG. 11 is a plan view of a plurality of assembled panels of a furtherembodiment of flooring system according to the present invention wherethe individual panels are triangular and there is provide an edge stripon each of the three sides.

In the drawings like characters of reference indicate correspondingparts in the different figures.

DETAILED DESCRIPTION

Reference is made to the above published application of Gibson whichshows and describes the details of the panels with the dividing stripsand the interconnection between the four corners of the panels.

The arrangement described herein comprises a floor system defined by aseries of panel members, four of which are shown at 10 through 13. Eachof the panel members has a top surface 16 defining a floor surface onwhich the user walks and providing an attractive appearance as describedhereinafter. Each of the panel members includes a bottom surface 17 forsitting on a sub floor of a conventional nature.

Each of the panel members is formed from a plurality of side by sidemain strips 10A to 10G which are connected together side by side to forman initial panel portion which has four side edges so that for examplethe panel 10 has side edges 20 and 21 which form a first pair of opposedside edges and side edges 22 and 23 which form a second pair of opposedside edges.

The main strips are formed from tongue and groove boards which arecommonly available and are formed from many different wood varieties.Thus each board has a tongue 18 on one side and a groove 19 on theopposite side arranged to inter-fit to hold the boards side by side.Such boards are supplied in various lengths which can include randomlengths and generally are supplied with tongue and groove ends so thatthe butting ands also inter-fit.

Each board conventionally has a chamfered edge 19A in the top surface 16where the boards meet to form a micro-groove between the two buttingchamfered edges.

In order to form these into a flooring system having an attractiveappearance, each base panel formed by the side by side boards hasattached two dividing strips which are attached to opposite side edgesof the panel. Thus for example the panel 10 has two dividing strips 30and 31 attached along the side edges 20 and 21. The dividing strips areformed from a board similar in appearance to the boards forming thepanel but is arranged at right angles to the boards so as to provide anattractive appearance in the floor when completed and laid.

Each dividing strip has a depth equal to the thickness of the boards sothat a bottom surface of the dividing strip is coincident with the planeof the bottom surface 17 and similarly a top surface of the dividingstrip is coincident with the plane of the top surface 16. The dividingstrips are preferably formed from the same boards as the main strips 10Ato 10G so as to have the same dimensions and the same appearance.

The panel 12 has the dividing strips indicated at 30A and 31A so thatthe panel 13 is rotated through 180° relative to the panel 10. In thisway the dividing strip 30A carried by the panel 13 engages the side edge23 of the panel 10 which is free from any dividing strips and is simplybare for butting the dividing strips 30A. Similarly the dividing strips31A butts the next adjacent panel not numbered.

The panel 11 is also rotated through 180° relative to the panel 10 sothat its bare edge 23A butts the dividing strip 31 and its dividingstrip 30A butts the edge 23B of the panel 13, In this way it will beappreciated that the whole floor can be laid by rotating the panels backand forth through 180° and laying them each to the next with the sideedges butting. In this way between each panel and the next adjacentpanel is one dividing strip thus separating the panels by the thicknessof the dividing strip while allowing the bare edge of the strip to buttagainst the outside surface of the dividing strip.

Each of the dividing strips extends along the full length of therespective side edge of the panel and also extends beyond the end of theside edge into a pointed portion 50. Thus as shown in FIG. 2 thedividing strip 30A is fastened to the panel 12 and the dividing strip 31is fastened to the panel 10. The dividing strip 30A extends to the endcorner 51 of the side edge 22A of the panel 13. The dividing strips 30Athen include the pointed portion 50 which is cut to form two side edges52 and 53 converging to an apex 54. The ends 52 and 53 are cut at 45°relative to the sides of the dividing strip so that they are 90° to eachother forming a right angle triangle converging to the apex 54 whichlies on a centre line 55 of the dividing strips 30A.

Symmetrically the dividing strip 30A includes an end portion 56 alsoconverging to an apex which touches the apex 54 at the center of therectangular area between the corners of the panels 10, 12 and thefurther two panels not numbered. In this way, in each of the squareintersections between the edges of the panels, each panel at theintersection carries one of the dividing strips with each of thedividing strips having the pointed extension portion symmetrical to theextension portion 50 and extension portion 56 projecting into the centerof the square area with the apexes of these pointed portions touching atthe center of the square area.

The panels are fastened to the sub floor 18 by screws 60 which arelocated in screw holes 61 located at the end of the respective dividingstrip spaced from the apex 54. Each panel has four such screw holes 61arranged adjacent the corners of the panel and spaced inwardly from theapexes of the dividing strips of the panel. Thus at each junctionbetween floor panels, four screw holes 61 surround the junction andprovide an attractive appearance, when those screw holes are plugged byvisually distinct plugs in known manner. Thus the dividing strips comingto a junction where the junction is visually distinct together with thesurrounding four holes of the screw pattern which are also visuallydistinct provides a visually distinct and attractive pattern across thewhole extent of the floor when laid.

Each of the strips 10A through 10G is of an equal common width and isformed from conventional floor planking so each strip has a grove 19 onone side and a tongue 18 on the other side of a conventional nature.

As shown in FIG. 1, some of the strips are continuous as indicated at10A and 10C so as to extend from the side edge 20 to the side edge 21.Others of the strips are discontinuous and include a join 36 between twoportions 36 and 37 of the strip. The joint 35 similarly includes atongue and groove arrangement 38 where a tongue at the end of the stripportion 36 is joined into a groove at the end of the strip portion 37.This provides an integrated structure throughout the strip but allowslengths of strip material to be used which are not necessarilycontinuous along the full length of the panel.

The divider strips are formed from a material of the same width and sameconstruction as the strips forming the panel. Thus each divider stripitself has a groove 40 along one side and a tongue 41 along the oppositeside. The divider strips are formed from a common source of the samematerial and generally therefore have the same width of the strips 10Athrough 10G and can be taken from the same supply. The divider stripsare therefore not visually distinct from the main strips but are visiblydistinguished by the right angle orientation.

In the alternative divider strips of a different width may be used andthe divider strips may be of a different wood variety thus providing avisually distinct pattern. Yet further the strips may be stained orcoloured to a different colour to provide a visually distinctarrangement as preferred by the user of the panels.

Most examples will have a divider strip that will be of the same widthand the same variety so that the whole panel can be formed from a commonsupply of the wood strip materials.

Use of wood is not essential in this construction but is obviouslypreferred to provide a high quality finished wooden floor product asopposed to laminate materials or other materials which are considered tobe of less quality.

The ends of the main strips 10 through 10 g are cut to form a groove 43at the edge 20 to receive the tongue 41 and symmetrically these stripsare cut to form a tongue 44 at the edge 21 to corporate with the grove40 of the divider strip 31.

A fastener arrangement for connecting each strip to the next adjacentstrip is shown in FIG. 3. Thus a series of fastener pins 150 is providedand these fastener pins are engaged into the tongue and groove jointbetween each main strip and the next adjacent main strip and between atleast some of the ends of the main strip and the respective dividerstrip.

Each pin 150 is of a type which has no head at a rear end 151 for theforward end 152 maybe pointed or may simply be straight to form astraight pin that can be simply driven into the wood at the joint usingconventional driving tools. Such pins are previously known and the toolsfor driving them are commercially available.

With this arrangement, however, the pin 150 is driven through the bottomsurface 17 and the pin is selected to have a length so that the rear end151 is recessed from the surface 17 after the application is complete.Thus the rear end 151 is recessed below an adjacent portion of thesurface 17 so if it is not proud of that surface then you've thepossibility of snagging or catching or damaging any materials.

The leading end 152 is arranged by selecting a length of the pin so thatthe leading end 152 engages into the adjacent board to a position beyondthe tongue 18.

The pin is driven at an angle to the surface 17 and therefore at anangle to the surface 16 so the pin passes through a plane P which joinsthe ends of the two strips indicated at 10A and 10B. Thus at thejunction fastened by the pin 150, which is one example of a series ofsuch fastened joints throughout the structure of the panel. The strip10A has a tongue 18 which is received within a groove 19 of the strip10B. The pin 150 has its rear end 151 in the strip 10B in the areaunderneath the groove 19 and passes from that area into the tongue 18,extending through the tongue and into the upper part of the strip 10Aabove the upper surface of the tongue 18. In this way the pin providesan effective fastening arrangement but the pin is wholly containedwithin the structure of the strips with neither the front end nor thetrailing end exposed beyond the surfaces 16 and 17. The angle of the pinrelative to the surface 17 is preferably of the order of 45 to 60degrees and more preferably 54 degrees. The fact that the pin extendsthrough the tongue 18 while the tongue is housed or contained in thegroove inhibits or prevents any splitting of the tongue during thepinning action.

Thus each strip is fastened to the next adjacent strip by a series ofsuch pins, the number of which can be selected depending upon structuralstrength required. In addition there is a connection between the ends ofsome of the strips 10A through 10G and the divider strip 31 whichextends similarly through the tongue 44 at the grove 40. The number ofsuch fastening pins can be selected again according to structuralstrength required so that only some of the ends of the strips arefastened or all of the ends or the strips are fastened as required.

Symmetrically further fasteners are inserted through the junctionbetween the tongue 41 and the groove 43 between the divider strip 30 andthe ends 20 of the main strips.

In this way the panel when completed is fixed in place and integrated bythe fasteners so that the structure is prevented from twisting by sideto side movement of the divider strips. It is preferred that theconnection of the panel is effected without the use of glue so as toavoid the necessity for application of glue during the manufacturingprocess, However glue or other additional fastening methods may be usedif required.

Turning now to the method of manufacture shown in FIGS. 4, 5 and 6,there are shown a serious of manufacturing stations through which thematerials pass to complete assembly of the structure as describe above.

Thus the manufacturing process includes a first assembly station 60, asecond convergence station 61, a fastening station 62, a cutting station63, a tongue and groove station 64, a carousel 65, and a final assemblystation 66.

In the assembly station 60, a number of channels 67 are formed eachcontaining a respective one of the strips 10A through 10G. Thus eachchannel 67A through 67G contains a respective one of the strips whichare fed forwardly in a continuous manner to the convergence station 61.The strips are introduced into the channel 67 so that they are incontinuous manner including the connection lines or joints 35. Eitherautomatically or manually at the assembly station, the strips areassembled so that the joint lines 35 are offset in a longitudinaldirection from each channel relative to the next adjacent channel sothat in this way no junction lines are arranged so that they are alignedor closely adjacent between side by side channels. This can be done inpractice by providing the channels of sufficient length that a skilledoperator can select the strips of different lengths and locate them sothat the joint lines 35 are longitudinally offset. If the strips are ofall identical length, this can be simply done by selecting the positionof the ends of the strips in a staggered manner at the outset and thestrips will remain in the staggered manner throughout the assemblyprovided the strips are carefully butted end to end and are all of acommon length. In the alternative strips of different lengths can beselected and the operator arranged to select required lengths to ensurethe required staggering of the butt joints.

Of course each strip in each channel has the groove and tongue arrangedso that the strips can be brought together and interconnected in theproper tongue and grove arrangement side by side.

From the assembly station 60 the channels are arranged to feed thestrips forwardly while at the same time converging those strips to bringthem together using a series of converging rollers 68. The strips arethus brought to a position immediately side by side and brought to aposition where the strips are compressed between a converging roller 69on one side and a compressing roller 70 on the other side. In thearrangement shown, the converging roller 69 carries a tongue 69A whichruns in the groove 19 on the right hand side of the assembled strips. Inthe convergence station there are series of such guide rollers 69indicated that 69B and 69C and these are arranged at a specific fixedlocation to provided a datum line which accurately locates the positionof the edge of the outside strip 10G and its grove 19.

On the opposite side of the datum line defined by the guide rollers 69,there is provided a cutting wheel 72 downstream of the compressionroller 70. The cutting wheel 72 is located at a fixed determineddistance from the guide rollers 69 to provide a cutting action on theedge of the strip 10A remote from the strip 10G.

The distance of the cutting wheel 72 from the datum line is accuratelyfixed and is slightly less than the minimum width of the convergedstrips 10A through 10G, bearing in mind that such strips whenmanufactured commonly have a significant manufacturing tolerance.

The cutting wheel 72 is arranged to cut a fresh tongue 15 and associatedshoulders 18A and 18B above and below the tongue 18. Thus instead ofrelying on the position of the tongue of the strip 10A, a fresh tongueand associated shoulders is cut so that the width of the convergedstrips is accurately equal to the distance between the cutting wheel andthe guide rollers regardless of any variations or tolerance in thewidths of the strips as supplied.

In this way the completed panel has a width between the sides 22 and 23which is accurately cut and is exactly equal for each subsequent panelthat is manufactured. In addition the amount of compression between thestrips is accurately maintained so that the strips are held at thisfixed spacing while substantially ensuring that any warping or bendingof the strips is removed by sufficient transverse compression across thepanel.

Downstream of the cutting wheel 72 is provided a guide roller 73 whichis arranged opposite to a respective guide roller 69C. The guide roller73 preferably contains a groove for receiving the tongue 18 recently cutby the cutting wheel 72. Thus the strips are maintained by these guiderollers and by further guide rollers 69D and 73A arranged downstream ofthe guide rollers 73 and 69C. These rollers are located at the fasteningstation 62 so that as the assembled panel formed by the individualstrips is moved into the fastening station 62 it is maintained at therequired fixed spacing and under the required compression.

At the fastening station 62 is provided a series of pin inserting toolsindicated at 62A through to 62F. These fastening tools are arranged atpositions bridging the junctions between the strips so as to be operableto insert the pins 150 at the required position and at the requiredangle.

The pin inserters 62A through 62F are controlled by a control unit 62G.The control unit receives inputs from a series of detectors 75A through75G which are arranged each in a respective one of the channels fordetecting the forwarding action of the respective strips. Each detector75 is arranged to detect the presence of a junction line 35. Thus thepin inserting devices 62A through 62F are controlled so that they areoperated at a time to ensure that a pin is inserted at a position spacedfrom a junction line 35 on either side of the pin. The controlled unitis arranged to determine a predetermined distance on either side of ajunction line 35 within which a fastener pin is not permitted to beinserted. The control unit is arranged to determine the positions ofinsertion of pins based upon the presence of the junction line 35 toensure that sufficient pins are inserted in the junction between eachstrip and the next adjacent strip while ensuring that the pins areinserted at a position spaced from the junction lines.

Downstream from the fastening station is provided a clamping assemblygenerally indicated at 76. This includes a pair of clamping members 77and 78 each on a respected side of the assembled fastened panel andwhich includes clamping engagements 79 which engage onto the sides 22and 23 of the assembled panel formed by the strips 10A through 10G. Thusafter the panel is released from the clamping rollers, is engaged byclamping members which are intended to hold that structure while it ismoved at right angles to the forming line into the further stations 64and 66. After the fastened panel formed by the panel is moved to up to arequired location and engaged by the clamping members 77 and 78, thisposition is detected by a sensor 80 which therefore locates the edge 20of the panel. At this position a cutting device 81 is operated whichmoves across the panel to provide a cutting action to define the sideedge 21. The cutting device includes a conventional blade 82 carried ona track 83 with the distance between the cutting blade and the sensor 80being accurately determined to ensure an accurate spacing between thesides 20 and 21 of the panel when cut.

As shown in FIG. 5, the panel so formed and fastened with the accuratespacing between the sides 20 and 21 and the accurate spacing between thetongue at the side 23 and the groove 19 at the side 22 is carried in thegripping members 77 and 78 on a suitable transport track (not shown),the formed panel defined by the main strips 10A through 10G is movedinto the tongue and groove station 64.

At the tongue and groove station 64, the panel supported in the clampingmembers 78 and 79 is moved along the track past a set of guide rollers85 and 86 which control the position of the edges 20 and 21 accuratelyin a predetermined spaced position. The guide rollers 85 and 86 includea second set 85A and 86A downstream thereof so that the panel ismaintained accurately positioned and accurately square. A tongue cutterwheel 87 is provided on the side edge 21 and a groove cutter wheel 88 isprovided on the side edge 20. These cutter wheels rotate relative to thepanel as it is moved past the cutter wheels to effect a cutter action toform at the side edges 20 and 21 the respected tongue and groovepreviously described.

After the formation of the tongue and groove, the completed panel formedby the main strips is moved into the final assembly station 66 at thecarousel 65.

The carousel 65 is shown in more detail in FIG. 6 and comprises a seriesof stations arranged around the carousel which rotates around a centralsupport 88. Thus the carousel defines a first station 65A at whichtongue and groove strip from a supply 65B is cut to a required length bya cutting device 65C. At a second station 65D; the cut length of thestrip is cut to define the pointed portion 50 at the front end. At athird station 65E, the cut strip is passed through a cutting station toeffect cutting of the pointed section 50A at the rear end of the strip.The cutting stations are of course arranged so that the length of thedividing strip now formed from the supply of the board is accurately tothe required length between the points of the pointed portions and thepointed portions have the accurate 90 degree angle. At the next station65F the formed dividing strip is passed through a set of cutting memberswhich form the chamfered edge 19A on the pointed portions 50 and 50A. Ata further station 65G, the dividing strip is drilled to form the holes61 at the base of the pointed portions 50 and 50A.

At a final station 65H, the completed dividing strip is moved intoposition onto the edge of the panel so that the groove in the dividingstrip engages onto the tongue of the side edge on one side of the paneland on the other side the tongue of the dividing strip is engaged ontothe groove at the side of the panel.

The carousel is of a conventional nature and uses conventional cutting,routing and drilling tools to effect the above cutting actions. Theselection of the necessary tools is within the skill of a person skilledin this art so that description of the necessary tools is not requiredhere. Carousels of this type are commonly available providing a seriesof stations. Of course the first carousel is arranged on one side andthe second carousel is arranged on the second side of the panel movedalong the track as carried by the clamping members 78 and 79.

At the final assembly station 66 including the two carousels 65 and 65X,there are provided additional pin driving members 62X, 62Y and 62Z fordriving pins as previously described into the junction between thedividing strip and the ends of selected ones of the main strips.

After the final assembly station 66, the completed panel assembled bythe pins is moved to a stacking station (not shown) where it is releasedfrom the clamping members 78 and 79 for stacking onto a pile of finishedsuch panels for transportation to a remote location for installation.

In FIG. 7 is shown an alternative arrangement for fastening the stripsof the panel member together and this comprises a sheet 90 of a fabricor similar flexible material which can be applied onto the whole of therear surface of the panel member so as to cover all of the joints withthe sheet being bonded to the rear surface 17 by a layer of an adhesive91. While it is preferred that a common sheet covers all of the jointsso that its dimension is substantially equal to the rear of the panel,it will be appreciated that separate strips can be applied along eachjoint or separate strips may cover some of the joints. Thus a singlepiece many be applied over the main strips when assembled and convergedat the fastening station and separate pieces applied over the joints ofthe divider strips in the final assembly station. The fabric pieces canbe unrolled from a supply of the required width and cut to length. Thestrips preferably carry the adhesive from the supply or the adhesive maybe applied separately. The adhesive may be a hot melt which is activatedby a heated plate or roller brought up onto the rear surface of theassembled panel which presses the fabric into engagement with the rearsurface and activates the adhesive.

Turning now to FIGS. 8 through 11, there is shown an alternativearrangement where the finished panel is a polygon which therefore has aplurality of sides converging to an apex where each side is arranged toco-operate with a side of next adjacent panel without any interveningdivider strips of the type described above.

Thus in FIG. 8 the panels 80 are hexagonal with a central panel section81 which is hexagonal and with an edge strip 82 at each side edge of thecenter section. Thus when a panel butts with another panel there are twobutting edge strips side by side as indicated at 82A and 82B, as opposedto the single divider strip of the above described arrangements. Eachedge strip butts at its end with its next adjacent strip at a butt line83 which is diagonal along a line 84 extending from a center of thepanel 81 as indicated at 85. The butt line may include tongue and grooveinterconnection or may be merely a flat butt.

The center panel is formed from side by side tongue and groove mainstrips as previously described. In view of the hexagon shape, whenarranged in a symmetrical manner, four of the edge strips extend in adirection at an angle of 120 degrees to the longitudinal direction ofthe main strips and two of the edge strips are parallel to the mainstrips. As an alternative it will be appreciated that, in anothersymmetrical arrangement, the main strips may be arranged at right anglesto those shown or may be at another angle intermediate the angle of thetwo symmetrical arrangements.

In FIG. 9, the panel 90 is square with two edge strips 91 parallel tothe main strips 93 and two edge strips 92 at right angles to the mainstrips 93. Again when a panel butts with another panel there are twobutting edge strips side by side. Each edge strip may butt at its endwith its next adjacent strip at a butt line which is diagonal, similarto the arrangement of FIG. 8 and FIG. 10, but in the example shown theedge strips 92 extend across the full width of the panel. The butt linemay include tongue and groove interconnection or may be merely a flatbutt. In the arrangement shown, the ends of the edge strips 92 includetongue and groove connections.

In FIG. 10, the panel 95 is also square with four edge strips 96 at anangle of 45 degrees to the main strips 97. Again when a panel butts withanother panel there are two butting edge strips side by side. Each edgestrip butts at its end with its next adjacent strip at a butt line whichis diagonal, similar to the arrangement of FIG. 8. The butt line mayinclude tongue and groove interconnection or may be merely a flat butt.

In FIG. 11, the panels 99 form an equilateral triangular shape withthree edge strips 100 two of which 101 and 102 lie at an angle of 60degrees to the main strips 100 and one of which 103 is at right anglesto the strips. Again, when a panel butts with another panel there aretwo butting edge strips side by side. Each edge strip butts at its endwith its next adjacent strip at a butt line which is diagonal passingthrough a center of the triangle, similar to the arrangement of FIG. 8.The butt line may include tongue and groove interconnection or may bemerely a flat butt.

In each case the edge strips present outwardly of the panel either atongue or a groove for engaging a groove or a tongue of an edge strip ofa next adjacent panel;

In each case the edge strips and the main strips are fastened togetherto form a common panel member for transportation and installation.

As shown, each of the main strips has the same width between the sideedges with each edge strip having substantially the same width as themain strips.

The dividing strips and the main strips are fastened together by the pinarrangement described above or by the adhesive sheet method describedabove.

Since various modifications can be made in my invention as herein abovedescribed, and many apparently widely different embodiments of same madewithin the spirit and scope of the claims without department from suchspirit and scope, it is intended that all matter contained in theaccompanying specification shall be interpreted as illustrative only andnot in a limiting sense.

1. A panelling system comprising: a plurality of panel members forlocating on a supporting surface generally edge to edge in an array tocover the supporting surface; each panel member having a front surfacefor defining an exposed surface of the panelling system, a rear surfacefor engaging the supporting surface and a plurality of side edges; eachpanel member comprising: a plurality of main strips arranged side edgeto side edge; each main strip having a tongue along one side edge and acorresponding groove along an opposed side edge; so that the main stripsare connected side by side by interconnection of the tongues and thegrooves; wherein the main strips have along a first end of the mainstrips a tongue and have along a second end of the main strips a groove;a first edge strip extending along the first ends of the main stripsacross at least some of the main strips; a second edge strip extendingalong the second ends of the main strips across at least some of themain strips; wherein each of the edge strips has a front surface of thedividing strip lying in a common plane with the front surfaces of themain strips to define the front surface of the panel; wherein each ofthe edge strips has a tongue along one side edge and a correspondinggroove along an opposed side edge; wherein the first edge strip has thegroove thereof engaged with the tongue along the first ends of the mainstrips; wherein the second edge strip has the tongue thereof engagedwith the groove along the second ends of the main strips; and whereinthe edge strips and the main strips are fastened together to form acommon panel member for transportation and installation.
 2. Thepanelling system according to claim 1 wherein each of the main stripshas the same width between the side edges.
 3. The panelling systemaccording to claim 2 wherein each edge strip has substantially the samewidth as the main strips.
 4. The panelling system according to claim 2wherein a longitudinal line along the main strips lies at an angle lessthan 90 degrees to a longitudinal line along an edge strip connected toends of the main strips.
 5. A panelling system comprising: a pluralityof panel members for locating on a supporting surface; each panel memberhaving a front surface for defining an exposed surface of the panellingsystem, a rear surface for engaging the supporting surface and aplurality of side edges; the panel members being of polygonal shape inplan view such that the panels can be arranged in an edge to edge arraycovering the supporting surface; each panel member comprising: aplurality of main strips arranged side edge to side edge; each mainstrip having a tongue along one side edge and a corresponding groove anopposed side edge; so that the main strips are connected side by side toform a center panel portion by interconnection of the tongues and thegrooves; the center panel portion being polygonal in plan view having anumber of sides; each of the sides having either a tongue or a groovetherealong; a plurality of edge strips equal in number to the number ofsides; wherein each of the edge strips has a front surface of thedividing strip lying in a common plane with the front surfaces of themain strips to define the front surface of the panel; wherein each ofthe edge strips has a tongue along one side edge and a correspondinggroove along an opposed side edge; wherein the edge strips are eacharranged in engagement with a respective side of the center panelportion with the tongue or groove thereof engaged with the groove ortongue of the respective side; wherein the edge strips present outwardlyof the panel either a tongue or a groove for engaging a groove or atongue of an edge strip of a next adjacent panel; and wherein the edgestrips and the main strips are fastened together to form a common panelmember for transportation and installation.
 6. The panelling systemaccording to claim 5 wherein each of the main strips has the same widthbetween the side edges.
 7. The panelling system according to claim 6wherein each edge strip has substantially the same width as the mainstrips.
 8. The panelling system according to claim 5 wherein alongitudinal line along the main strips lies at an angle less than 90degrees to a longitudinal line along an edge strip connected to ends ofthe main strips.
 9. The panelling system according to claim 5 whereinthe main strips define an area which is square with four sides eachreceiving a respective edge strip.
 10. The panelling system according toclaim 5 wherein the main strips define an area which is triangular withthree sides each receiving a respective edge strip.
 11. The panellingsystem according to claim 5 wherein the main strips define an area whichis hexagonal with six sides each receiving a respective edge strip. 12.The panelling system according to claim 5 wherein the edge strips haveends butting at a line extending outwardly from an apex of the centerpanel portion.
 13. The panelling system according to claim 5 wherein theline extending outwardly from the apex intersects a center of the panelso that the edge strips are symmetrical.
 14. The panelling systemaccording to claim 5 wherein the dividing strips and the main strips arefastened together by a plurality of pins each inserted at a butting edgebetween one strip and a next adjacent strip through the rear surface ata groove on one side of the butting edge and extending into a tongue inthe groove with a front end of the pin terminating at a position spacedfrom the front surface.
 15. The panelling system according to claim 14wherein each pin is inclined at an angle to a plane containing thebutting edge so as to pass through the plane.
 16. The panelling systemaccording to claim 14 wherein each main strip is fastened to each nextadjacent strip by a plurality of the pins at spaced positions along themain strips and each dividing strip is fastened to the main strips by aplurality of the pins at spaced positions along the dividing strip. 17.The panelling system according to claim 14 wherein each pin is insertedsuch that it is countersunk from the rear surface.